Method of making composite articles



May 16, 1933- B. BRoNsoN 1,908,682

METHOD 0F MKING COMPOSITE ARTICLES Original Filed Dec. 20. 1929 ,24 2.9 g4 26 .sa f

21ML/ /m/ Patented May 16, 1933 UNITED STATES PATENT lOFFICE BUDD BRONSON, OF CLEVELAND, OI-IIO, ASSIGNOR-TO THE OHIO RUBBER COMIKANY, OE CLEVELAND, OHIO, A. CORPORATION OF OHIO METHOD 0F MAKING COMPOSITE ARTICLES Original application iled December 20, 1929, Serial N o. 415,384. Divided and this application filed May 12,

1932. serial No. 610,902.

This invention relates to composite articles, such as rubber surfaced mats and the like, and to a novel method of making these articles.

This application is a division of my copending original application Serial No. 415,384, filed December 20, 1929.

Rubber surfaced mats for vehicle floors and other uses, as heretofore constructed, have been formed with an exposed layer of felt, or other resilient material, secured to the under surface of a sheet of rubber. During use of this form of mat construction, the resilient material invariably mats down and loses its cushioning effect. This material also collects dust and moisture, and usually upon becoming wet emits objectionable odors.

In overcoming these difliculties I have devised a mat construction wherein an envelope is provided for the resilient material, and it may be regarded as an object of this invention to provide a novel method for the production of composite articles of the type having resilient material-sealed and encased between layers of rubber. l

It is also an object of this invention to provide a novel method of making composite articles, according to which pressure fluid is confined between the sheets of covering material during the vulcanizing operation.

A further object of this invention is to provide a novel method of making rubber surfaced resilient mats, in which matting of the resilient material is prevented by introducing fluid pressure between the sheets of covering material substantially simultaneously with the closing of the vulcanizing mold.

The invention may be further briefly summarized as consisting in certain novel methods and steps of procedure, hereinafter disclosed and particularly set out in the appendocL claims.

In the accompanying sheet of drawing,

Figure 1 is a top plan view of the composite article of my invention.

Fig. 2 is a fragmentary sectional view taken on line '2--2 of Fig. 1.

Fig. 3 is a sectional view taken on line 3-3 ofFig. 1.

vehicle ioor mat, and have illustrated diai grammatically the lmanner of carrying out the method of Vmy invention, but it should be understood, however, that my invention is not limited to the particular apparatus and steps of procedure disclosed since these are susceptible of changes whereby they can be applied to the production of various composit structures. l

The mat 10, which I have -illustrated,vcom

prises'top and bottom sheets of rubber 11 and 12 vulcanized in contact with' oppositesurfaces of a layer of resilient material 13 interposedtherebetweem Marginal portions of the top and 'bottom sheets'extend' beyond the edges of the layer 13 and are vulcanized'together, as clearly shown in the dra-wing, to form the marginal portion 14,of the mat. The layerV 13 may be constructed of any suitable yielding material such as felt, sponge rubber, or the like. vDuring the vulcanizing operation, if desired', the surface of the top sheet 11 may be provided with corrugations or with any ornamental pattern or configuration. drawing is intended for use in the front compartment o-f a motor vehicle, and is accordingly provided with openings therethrough to accommodate the usual operating levers and pedals. Portions of the sheets 11 and 12 are also vulcanized together to provide mar# ginal portions 15 around these openings, sim-- ilar in form toy the marginal portions 14. formed around the outer edge of the mat.. Thus it will be seen thatthe top and bottom sheets completely encase the layer of resil- The form yof mat illustrated in the.

ient` material within an air-tight pocket.

silient characteristic of this material is rctained throughout its useful life.

Ordinarily, when a `Hoor covering is fitted to the front compartment of a motor vehicle, the covering must be bent along a transverse line corresponding with the line of intersection between the surface of the inclined toe board and the surface of the usual horizontaly portion of the floor. When the covering is made up of layers of material the bending upwardly of the portion of the mat which is to i to the compartment iioor these grooves permit thefront portion of the mat to` readily adjust itself to the inclination ofthe toe boa-rd as indicated in dotted lines in Fig. 2. vVvhile I show the layer of resilient material compressed between the sheets of rubber along the V-shaped grooves, it maybe desirable to cut or separate the layer of resilientma'terial into two pieces along this line, in which case the portions of the sheets which form the grooves would be vulcanized together.

The Hoor mat which I have illustrated may be constructed in various ways, and in Figs. 4:' and 5 of the drawing, Ihaveillustrated one method which may be employed.v According to this method a layer of suitable resilient material. such as alayer of felt 18. is placed in a mold member and is covered witha sheet of uncured rubber. By a molding and vulcanizing operation the uncured rubber forms rial, thepartiallvconstructed mat ris placed in a suitable mold 20 on top of a sheet of uncured'rubber. After closing the mold the sheet of uncured rubber is vulcanized in contact with the layer of resilient material to form the bottom sheet 21 which is molded and attached around its edge portions 22 to the top sheet 19, as indicated in Figs. 4 Vand 5.

For the operation of molding and vulcanizing the bottom sheet, the mold is provided with a recess 23 of suflicient depth to prevent `secured together around their edges.

the application of heavy pressure against the sheets which would result in matting of the resilient material.

According to another method of my invention, composite articles may be constructed with an encased resilient layer formed of sponge rubber. In making this composite structure, the layer of sponge rubber is inter-` posed between the sheets of uncured rubber and in the curingoperation, the top and bottom sheets of rubber are vulcanized in contact with the layer of sponge rubber, and alre T e heat applied to the work during the vulcanizing operation causes gases to be given off by the sponge rubber, and since the edge p0rtions of the sheets are in sealing engagement and preventthe escape of these gases, pressure is built up in the pocket between the sheets. lThis pressure confined betweenl the top and bottom sheets of the work opposes the pressure applied to these sheets by the mold members and thus prevents matting of the fibers of the sponge rubber.

In Fig. 6 of thedrawing, I have illustrated another method which may be employed in the manufacture of composite structures. According to this method, top and bottom sheets ofuncured rubber 24 and 25 having a layer of resilient material 26 interposed therebetween are placed in a mold comprising mold members 7 and 28. Upon movement'of the mold members to close the mold, nozzles 29 and 30 provided in suitable nume ber on one of the mold members, pierce the bottom sheet 25 and extend into the layer of resilient material. VA suitable connection 3l supplies suitable iuid pressure, such as compressed air', through the nozzle 29 into the l canization of the rubber, and for the forma- I tionof the pattern or ornamental design which is to appear upon the top surface of the finished artic-le. A suitable connection 32 connects the nozzle 30 with a vacuum pump, or exhausted chamber, so that substantially simultaneously with the opening of the press, the fluid pressure confined between the sheets can be withdrawn, or released.

After the article has been removed from the mold, the holes formed by the nozzles exe tending through the bottom sheet may be cemented shut, or otherwise closed in any suitable manner, s o that the rubber covering which encases the layer of resilient material r will be air-tight.

It will now be readily seen that the resilience of the composite articles constructed according to my invention, is not impaired by matting down of the fibers during the construction of the article. It will also be seenthat by encasing the layer of resilient material within an air-tight pocket formed between the cover sheets, the collection of dust and moisture is prevented with the result that the resilient material remains clean and dry and retains its cushioning effect indefinitely. It will also be apparent that the construction which I have provided permits the mat to be readily handled without disintegration, and also permits it to be washed or otherwise cleaned without resulting in damage or deterioration of the resilient material.

In disclosing my invention I have illustrated and described a floor mat for a vehicle compartment, but obviously mats constructed according to my invention may be made of any desired shape or size. Likewise, it is obvious that their useful application is not limited to vehicle floors, since they may be used on stairways, hospital floors, or wherever a yielding and cushion-like covering is needed.

In the disclosure of my invention, I have referred to felt as being suitable for the layer of resilient material, and by this term I mean any of the commercial felts formed of matted fibers, such as jute, either with or without a strip of burlap or other woven material incorporated therein.

vWhile I have described the method of my invention in a detailed manner, it should be understood, however, that I do not intend to limit myself to the use of the precise steps of procedure disclosed, but that I regard my invention as including such changes and modifications as do not involve a departure from the spirit of the invention and the scope of the appended claims.

Having thus described my invention, I claim:

l. The method of making composite articles which comprises molding and vulcanizing sheets of rubber in contact with opposite surfaces of a layer of yielding material, and maintaining fluid pressure between said sheets during the vulcanizing operation to prevent matting of said yielding material.

2. The method of making composite articles which comprises molding and vulcanizing sheets of rubber in contact with opposite surfaces of a layer of yielding material, and introducing fluid pressure between said sheets substantially simultaneously with the closing of the mold to prevent matting of said yielding material during the vulcanizing operation.

3. The method of making composite articles which comprises molding and vulcanizing sheets of rubber in contact with opposite surfaces of a layer of yielding material, maintaining fluid pressure between said sheets during the vulcanizing operation to prevent matting of the yielding material, and relieving said pressure substantially simultaneously with the opening of the mold.

4. In a method of making composite articles embodying a resilient pad and a covering for the pad, the steps of pressing the covering against the pad to unite the same, and maintaining fluid pressure within the body of the pad during the application of pressure.

5. In a method of making composite articles embodying a fibrous cushion and a covering for the cushion, the steps of pressing the covering against the cushion to unite the same, and maintaining fluid pressure within the body of the cushion during the application of pressure to prevent matting of the fibers.

6. The method of making composite articles embodying a fibrous pad and a rubber covering for the pad, which comprises applying heat and pressure to the rubber covering to mold and vulcanize the same in contact with the pad, and maintaining fluid pressure within the body of the pad during the application of pressure.

7. The method of making floor mats emr bodying a fibrous pad and a rubber covering for the pad, which comprises molding and vulcanizingV the vrubber covering in contact with the pad, and maintaining fluid pressure in the body of the pad to prevent matting of the fibers and for cooperation with a portion of the mold in applying molding and vulcanizing pressure to the rubber covering.

8. The method of making mats embodying a fibrous pad and rubber covering for top and bottom surfaces thereof, which comprises vulcanizing the rubber covering in contact with the pad, and maintaining fluid pressure in said pad to prevent compression thereof and for cooperation with portions pressure to the rubber covering Without compressing said pad.

In testimony whereof, I hereunto aliiX my signature.

BUDD BRONSON.

IGS 

